Wood gasifier

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Project: Create a Wood Gasifier for Vietnam Lecturer: Dr. Peter Stammnitz Group 2: Đng Tiu My- Factory planner Trn Kim Ngân- Economist Trương ThXuân Đào- Project coordinator NguynHng Khánh- Factory planner Nguyn Kim Ninh- Manufacturing expert Nguyn Quang Thanh-Designer April 2014 1

Transcript of Wood gasifier

Page 1: Wood gasifier

Project:Create a Wood Gasifier for VietnamLecturer: Dr. Peter Stammnitz

Group 2:Đặng Tiểu My- Factory plannerTrần Kim Ngân- EconomistTrương Thị Xuân Đào- Project coordinatorNguyễn Hồng Khánh- Factory plannerNguyễn Kim Ninh- Manufacturing expertNguyễn Quang Thanh-Designer

April 2014 1

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Introduction

• Bio char can use as fertilizer when mixed with compost.

• Affordable design will encourage people use clean cook stoves .

• Reduce pollution because burning crop residue by Gasifiers only produces CO2

Solution: The role of Gasifiers

• Enormous demand of fertilizer because of soil degradation problems.

• Prefer cheaper but toxic coal cook stoves due to costs of LPG are rising.

• Burning crop residue is polluting the environment.

Consequences

• 79.5%(*) total land use is agricultural land.

• 68%(*) population lived in rural can not afford the LPG cookstove

• Heavily dependent on agriculture (69.5%(*) of labour force).

Facts

(*) Viet Nam statistics book 2012 2

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Application of biochar

Bio char

Produce a soil

enhancer

Produce clean,

renewable energy

Reduce agricultural

waste

Fight global warming

(*) http://www.biochar-international.org 3

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Part one

1 • Analysis material

2• Technical solutions

3• Analysis markets, prices, costs

4• Procurement analysis, sales strategy

5 • Stakeholder, value, jobs,protection of resources

6• Exist practical experiment results

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Rice husk and straw• Location: 20% in Red river delta and 50% in Mekong river delta.• Current usage: Cooking (15%), brick kiln (40-45%),power plant, briquette (10%),

left over (20-25%)

Sugar cane• Location: Mekong River Delta, North Middle and Coastal Plain, and East South• Current usage: 50-60% combustion in Furnace, fertilization

Corn cobbLocation: 50% Northeast and 10% in south east

• Current usage: animal feed, cooking, fertilizer

Coconut husk• Location: 84% in Mekong Delta (Ben Tre 30%)• Current usage: 100% shell: activated carbon or domestic fuel or industrial thermal.

96% husks: processed into coir

Coffee husk• Location: the Central Highlands and the North• Current usage: Combusted, fertilizer, dumped

*Biomass Business Opportunities Viet Nam by SNV Netherlands Development Organisation Vietnam

Analysis of material in Vietnam*(2/2)

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Analysis of material in Vietnam*(2/2)

Material Area ( Ha) Yield / Ha % residue TheoreticalAvailability

Rice husk

7,500,000 ha 5.32 t/ha20% 8 million ton

Rice straw85% (on average) 23 million ton

Sugar cane 266,000 ha 63.9 t/haTop: 30%, leaves:10%, Bagasse: 9%

Top: 4,110,150t;Leaves: 1,370,050t;Bagasse: 1,233,045t.

Corn cobb 1,125,000 ha 4.0 t/ha 20-50% 1,066,500 tons

Coconut husk 130,000 ha 13 t/ha 30% weight is

husk 975 tons

Coffee 500,000 1.8 t/ha 15% of the driedcherry weight 135,000 tons

*Biomass Business Opportunities Viet Nam by SNV Netherlands Development Organisation Vietnam

Conclusion: Rice straw can be identified as the largest potential.

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Sustainable rice straw material flow

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Part one

1• Analysis material

2 • Technical solutions

3• Analysis markets, prices, costs

4• Procurement analysis, sales strategy

5 • Stakeholder, value, jobs,protection of resources

6• Exist practical experiment results

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Technical principle(*)

The updraft gasifier• Pros: Small pressure drop, good thermal efficiency, little tendency

towards slag formation• Cons: Great sensitivity to tar and moisture and moisture content of

fuel, poor reaction capability with heavy gas load.

The downdraft gasifier• Pros: low sensitivity to charcoal dust and tar content of fuel, flexible

adaptation of gas production to load.• Cons: Design tends to be tall, not feasible for very small particle size

of fuel

The Crossdraft gasifier• Pros: Short design height, very fast response time to load, flexible

gas production• Cons: Very high sensitivity to slag formation, high pressure drop.

(*) “Alternative Energy in Agriculture”, Vol. II, Ed. D. Yogi Goswami 9

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Existing technical solutions(*)

Rocket stovePro: need less fuel, produce clean airCons: Must be used with a thermal mass for efficiency

Anila stovePro: very sturdy, easy to learn to use, works fineCons: not work well on clearly sub zero temperatures

Biochar rocket stovePro: can be used in door, easier to control the temperature Cons: increased emissions, possible incomplete pyrolysis

TLUD stovePro: absence of smokeCons: not ideally suited for use indoors

(*) http://www.soil-carbon-regeneration.co.uk/biochar/biochar-stoves-2/ 10

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Part one

1• Analysis material

2• Technical solutions

3 • Analysis markets, prices, costs

4• Procurement analysis, sales strategy

5 • Stakeholder, value, jobs,protection of resources

6• Exist practical experiment results

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Gasifier market Target groups: potential customers are farmers in

the Northern Highlands, Central Highlands, and Mekong Delta(*), especially ethnic minority groups who only can afford cook stoves with little to no subsidies.

In 2012, population in rural area is 60416,5 thousand person, with six members per household on average. Therefore, the number of rural households in Vietnam was about 10 million.

In conclusion, the Gasifier market is estimated up to 10 million.

(*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 12

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Biochar Market

Agricultural land

26280,5 thousand ha

Application of 0.5ton biochar/ha

/year(*)

Quantity of biochar on

demand: 13.14 thousand ton/year

(*) http://internationalinventjournals.org/journals/IJASS 13

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Biochar cost analysis

Biochar cost: 2.250 VND/kg

Risk ratio: 0.5

Costs toward rice straw

material: 300 VND/kg

Yield of biochar was

approximately 20-23% (*)

(*) http://www.biochar-international.org/profile/Stoves_in_Vietnam 14

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Gasifier cost analysis

Gasifier cost: 600,000 VND

Labour cost:

150000 VND

Material cost:380.000VND

Manufacturing overhead:

70000VND

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Part one

1 • Analysis material

2 • Technical solutions

3 • Analysis markets, prices, costs

4 • Procurement analysis, sales strategy

5 • Stakeholder, value, jobs,protection of resources

6 • Exist practical experiment results

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Procurement

Material Price Technical data

Mild steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm

Stainless steel sheet 13500vnd/kg 5,0 x 1500 x 6000mm

Roll steel 14500vnd/kg Ø8xroll

Rectangular steel 14500vnd/kg 4x40x100mm

Rectangular steel 14500vnd/kg 2.5 x25x25mm

Rectangular steel 14500vnd/kg 2x30x30mm

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Sales & Distribution Strategy(*)

• The Northern Highlands, Central Highlands, and Mekong Delta

• Choose regions that have potential for longitudinal effects,

Determine which target regions

• Create incentive commission structure that motivates the promoter to encourage wide-scale adoption

Determine specific promoters have the best reach within

target regions

• Understand which channels have the best reach within target communities

• Focus on word-of-mouth marketing, which is key in Vietnam culture

Create marketing campaign to establish

branding and generate awareness

(*)Vietnam Market Assessment by Global Alliance for Clean Cook stoves 18

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Part one

1• Analysis material

2• Technical solutions

3• Analysis markets, prices, costs

4• Procurement analysis, sales strategy

5• Stakeholder, value, jobs, protection of resources

6• Exist practical experiment results

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Stakeholders analysisStakeholder Problem/

ConstrainMain Interest Potential

Projectgroup

Short of timeFinance securePractical experience

Profitable business but sustainabledevelop

Knowledge to approach new technology

Rural community

Lack of skillPovertySoil degradation

Increase income, Improve living qualification but low cost

Agricultural waste

Government Pollution, Soil degradationPressure on energy demand

Renewable energy,poverty reduction

Power of policymaker

ForeignNGOs

Direct contact to local people, unfamiliar to local habit

Sustainable rural development

Funding, project management experience

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Our Gasifier remarkable value

Raw material

Production

Sales and distributionMaintenance

Product development

Gasifier

Stable supply, low cost

Low cost, portable,

easy to use

Provide training in self-repair

sustainable business models

Affordability ,last mile distribution, self-built construction

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Job Creation ValueTransfer technologyto customers, farmers…

Built plant local labor absorption

(http://pamoja.se/)

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PROTECTION OF RESOURCES (1/2)

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PROTECTION OF RESOURCES (2/2)

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Part one

1• Analysis material

2• Technical solutions

3• Analysis markets, prices, costs

4• Procurement analysis, sales strategy

5 • Stakeholder, value, jobs,protection of resources

6• Exist practical experiment results

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Result of Biochar Treatment and its Effects on Rice and Vegetable Yields in Mountainous Areas of Northern Vietnam (*)

“Application of 0.5–2.5tons biochar/ha combined with NPK, average rice yield was increased by 17.6%.

Economic benefit from rice cultivation is estimated by 29.11- 37.05 million VND/ha/crop with net income of 2.64- 7.26 million VND/ha/crop.”

(*) by Vinh NC. , Hien NV., Anh MTL., Johan Lehmann, Stephen Joseph 26

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Results of comparison test of CARE Vietnam

Gasifier stove Open fireThe amount of used wood (gram)

955 - 1235 2000

Total weight of food (gram)

1850 1850

Total weight food/total weight wood

1.5 – 1.94 0.93

Total time for cooking rice to simmer (minutes)

29 - 34 32

Conclusion: in the same period of time, with less used wood (955 to 1235 gram), gasifier stove can cook the same weight of food as the traditional open fire with 2000 gram. 27

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Part two

1• Creation of Design

2• Design for manufacturing

3• Factory planning

4• Further expand project recommendation

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Productivity (to generate

charcoal)Life time Indoor usable

Low cost Rapid heat transfer Safety

Portable Easy to ignite Cleanliness

MachinableFlexible with

various biomass

Easy to remove charcoal

Product requirement and technical specific

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Evaluation for best solution

Rocket stove TLUD stove

Anila stove30

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No Requirement Weight (%) TULD stove

Anila stove

Biochar rocket stove

1 Low cost 20 2 3 12 Portable 15 3 3 13 Easy to remove charcoal 10 2 3 14 Cleanliness 10 2 3 15 Productivity 10 3 2 1

6 Flexibility with raw material 5 1 1 3

7 Usable indoor 5 3 3 18 Easy to ignite 5 2 3 19 Rapid heat transfer 5 3 3 110 Life time 5 1 2 311 Safety 5 2 3 212 Machinable 5 2 3 1

Total 100% 225 275 125

Base on above analysis, we select Anila stove type to improve such feature for high adaptation with the requirement.

Evaluation for best solution

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Principle Sketch Cross section

Principle sketch

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Fuel

Biomas Biomas

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Ambient Air Hot Air

Fan

Heat Exchanger (Optional)Heating by burning charcoal indoor cause many

deaths in winter in North Viet Nam

Our heat exchanger provide rural community a environmental and economic heating

solution33

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Laminar Flow

Temperature higher in centre.

Insulating film on Tube surfacePoor heat transfer

Turbulent Flow

Good mixing

Breaks down insulating film

Better heat transfer

Spiral Tubes34

Comparing between Spiral Tubes and Straight Tubes

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01.Top lid

02. Biomass chamber

03. Outer housing 35

Height: 600mmWidth: 420mmWeight: 25kgBiomass volume: 37 dm3

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Part two

1• Creation of Design

2• Design for manufacturing

3• Factory planning

4• Further expand project recommendation

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Bill of material

Biomass chamber coil

Combustion chamber coil

Outer housing

Bottom plate

Biomass chamber legs

Cover plate

Top lidBiomass chamber lid

Combustion chamber

Biomass chamber

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Top lid Pot standTop Lid and Small Lid

Part Name Technical specific Material Process

Top lid Outer diameter: 430Inner diameter: 150Thickness: 2

Mild steel sheet CuttingDie Forging

Pot stand Length: 100Width: 30Thickness: 2

Rectangularsteel

Cutting

Biomass chamber lid

Outer diameter: 370Inner diameter: 100Thickness: 2

Mild steel sheet CuttingDie Forging

Biomass chamber lid handle

Length: 25Width: 25Thickness: 2

Rectangularsteel

Cutting

PROCESS FOR PRODUCE SINGLE COMPONENT

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Biomass chamber (1/2)

Part Name Technical specific Material Process

Biomass chamber tube

Diameter: 360Height: 380Thickness: 2

Stainless steel sheet

Sheet cuttingFormingWelding

Biomass chamber coil

Diameter: 380Pitch: 50Revolution: 6

Roll steel Forming

Bottom plate Outer diameter: 360Inner diameter: 80Thickness: 2

Stainless steelsheet

Die forging

Biomass chamber leg

Height: 135Length: 50Width: 30

Rectangularsteel

Cutting

Biomass chamber tube

Biomass chamber coil

Bottom plate Biomass chamber leg

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Combustion chamber

Part Name Technical specific

Material Process

Combustion chamber

Height: 420Diameter: 100Thickness: 210 Hole: D=30

Stainless steel tube

CuttingDrilling

Combustion chambercoil

Diameter: 96Pitch: 50Revolution: 6

Roll steel Forming

Combustion chamber

Combustion chamber coil

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Cover:

Part Name Technical specific Material Process

Outer housing Diameter: 420Height: 550Thickness: 2

Mild steel sheet

CuttingDrillingForming

Bottom plate Diameter: 420Thickness: 3

Stainless steel sheet

Cutting

Handle Length: 160Width: 66Thickness: 3

Bar steel Cold forging

Outer Housing

Bottom plate

Handle

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Sub Name

Part Name Process Equipment

1 Top lid + Pot stand Arc welding MIG Welder

2 Biomass chamber lid + Biomass chamber lid handle

Arc welding MIG Welder

3 Biomass chamber tube + Biomass chamber coil

Arc welding MIG Welder

JOINING PROCESS

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Sub Name Part Name Process Equipment

4 Combustion chamber + Combustion chamber coil

Arc welding MIG Welder

5 Bottom plate + Biomasschamber leg

Arc welding MIG Welder

6 Sub 4 + Sub 5 Arc welding MIG Welder

JOINING PROCESS

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Sub Name

Part Name Process Equipment

7 Sub 3 + Sub 6 Arc welding MIG Welder

8 Sub 7 + Cover Plate Arc welding MIG Welder

9 Cover housing + Handle Arc welding MIG Welder

10 Sub 8 + Sub 9 (Finish) Arc welding MIG Welder

JOINING PROCESS

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Equipment and Machinery

http://kzwmachine.en.hisupplier.com/product-161793-steel-tube-cutter.html

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http://www.asia.ru/en/ProductInfo/1341682.html

http://www.rexhydraulics.com/general/Gallery.aspx?gid=14

http://www.alibaba.com/product-detail/air-hammer_338304017.html

Forging machine

http://www.directindustry.com/prod/steeltailor/portable-cnc-plasma-cutting-machines-35080-1172087.html

Cutting machineHydraulic plate rolling

machine

Drilling machine

MAG/MIG welding machineSteel tube cutter

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Part two

1• Creation of Design

2• Design for manufacturing

3• Factory planning

4• Further expand project recommendation

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Production programs planning

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Production programs planning

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ProductionProgram

Cutting Joining InspectionPackingFormingForming

Market forecast

Supplier 1

Supplier 2

Customer A

Customer B

Aaaaaa

• Implement the flow assembly: ‘one piece flow’• Highest flexibility on customer demand• Reduction of space, inventory and throughput time

Shipping

3 people 2 people 3 people 2 people

Cutting

Cutting

Cutting

C/T306s C/T312s C/T295s C/T280s

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Capacity Planning

Population in Thai Nguyen: 1.1 millionPopulation in rural area: 0.8 millionDemand: 130 thousand productsFirst phase: 5 yearsCapacity: 26,000 products/year

90 products/day(300 working days/year)

Thai Nguyen is selected as first market due to:- Many experiments gasifier conducted in Thai Nguyen.- Local community’s awareness toward gasifier- Concentrates ethnic minorities.

Second phase: copy the first model from Thai Nguyen to Thanh Hoa after 2 years of first phase

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Material flow in factory

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Factory layout

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Factory layout

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Organisation chart

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Director1 person

Accountant1 person

HR1 person

R&D2 persons

Production12persons

Cutting2 persons

Drilling1 person

Forming2persons

Joining3 persons

Inspect2persons

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Part two

1• Creation of Design

2• Design for manufacturing

3• Factory planning

4• Further expand project recommendation

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Expanding objective customers

1. BBQ restaurantsExisting restaurants and their current technologies : BBQ garden, Sumo

BBQ, Hana BBQ, BBQ Smoke, BBQ straw, …

Using char coal Using gas stove

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Advantages of using gasifier stove

- Reduce cooking fuel expenditure :Material: compressed rice husk

(1620VND/kg),rice husk firewood (1290VND/kg), …Compared with: coal : 5000VND/kg

gas : 400 000VND/12kg

- Friendly environment -> Sustainable development-> Establish good reputation.

- No harmful exhausted gas

Expanding objective customers

1. BBQ restaurants

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* Nowadays, people show their deep concernabout the environmental protection, especiallyeducated people, who have potential to possessour green villas project.

* Main reasons:- Harmful vegetable by overuse pesticide as well

as chemical fertilizer.need clean vegetable.- Energy saving- Establish good reputation

Expanding objective customers

2. Project to build green villas

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Expanding objective customers

Project to build green villas

Using gasifier stove for cooking (Material: compressed rice husk, … bought from the market)

Using biochar for planting vegetable on garden around

Utilize heat from the output gas for heater or heating pool

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Gasifier market: up to 10 million/year. Biochar market: over 13 thousand

tons/year. Technical solution: “Improved “Anila

Gasifier. Target cost: 600.000VND/gasifier

(approximately 29 USD). Factory capacity: 90units/day

Project Summary

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THANK YOU FOR YOUR ATTENTION

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